Fuel transporting tube

Description

[0001] The present invention relates to a fuel transporting tube and particularly to such a tube which has a laminated structure including a plurality of layers, which exhibits an excellent resistance to permeation of fuels, e.g., not only gasoline but also alcohol-blended gasoline, an excellent detergent resistance, and an excellent hydrolysis-deterioration resistance, and exhibits an excellent resistance to interlayer separation when being used in a high-temperature atmosphere, and which is particularly suitable for use in a fuel-transporting piping system of an automotive vehicle.

[0002] A fuel-transporting piping system of an automotive vehicle includes a feed tube, a return tube, an evaporator hose, a breather hose, a filler hose, an ORVR-tube, or the like. Conventionally, various sorts of metallic, rubber, or resinous tubes or hoses have been used in the piping system. Recently, resinous tubes are widely used in consideration of cost performance, in particular. Meanwhile, national regulations regarding fuel evaporative emission have been stricter and stricter in consideration of environmental problems. That is, it is strongly desired to minimize the amount of fuel that permeates through the tubes and transpires into the atmosphere.

[0003] In United States of America, alcohol-blended gasoline is commercially used as a fuel of automotive vehicles. Generally, the amount of alcohol-blended gasoline that permeates out through a resinous or rubber tube is much more than that of non-blended gasoline that does not contain alcohol. Thus, it is desired to develop a tube which has an excellent resistance to permeation of not only non-blended gasoline but also alcohol-blended gasoline.

[0004] Various proposals have been made in the above-indicated background. For example, Japanese Patent Document TOKU-KAI-HEI No. 4(1992)-224384 discloses a fuel transporting tube including, as its fuel barrier layer, an innermost layer which is formed of a polyester resin such as polyethylene terephthalate or polybutylene terephthalate, and U.S. Patent No. 5,425,817 discloses a multi-layer plastic tube including an innermost layer and an outermost layer each of which is formed of a polyamide, and including, as a low-permeation layer, an intermediate layer which is formed of a linear-crystalline polyester such as polyethylene terephthalate or polybutylene terephthalate. In addition, Japanese Patent Document TOKU-KAI-HEI No. 6(1994)-23930 discloses a multi-layer polymer hose or pipe including an innermost layer and an outermost layer each of which is formed of a polyamide, and including, as a low-permeation layer, an intermediate layer which is formed of a polyester resin such as polyethylene terephthalate, polybutylene terephthalate, or polyethylene naphthalate, and European Patent Application No. 0686797 A1 discloses a multi-layer plastic tube including, as a low-permeation layer, an innermost layer which is formed of a thermoplastic polyester such as polyethylene terephthalate or polybutylene terephthalate.

[0005] However, even the above-indicated multi-layer or laminated tubes that are claimed to be resistant to permeation of alcohol-blended gasoline, do not satisfactorily meet the currently desired, very strict requirement regarding the resistance to permeation of alcohol-blended gasoline, even if those resins disclosed in the prior documents may be selected anyway.

[0006] Out of the above-indicated tubes, ones whose innermost layer is formed of polyethylene terephthalate or polybutylene terephthalate are deteriorated, during a long period of use, because of an amine detergent that is usually added to a fuel for the purpose of removing stains of an intake valve. That is, those tubes do not exhibit a sufficiently high detergent resistance. In addition, tubes whose innermost layer is formed of one of the resins disclosed in the prior documents do not exhibit a sufficiently high resistance to hydrolysis of innermost layer. More specifically described, the innermost layer may be hydrolized because of water contained in the fuel, or moisture present in the atmosphere. Therefore, those tubes do not exhibit a sufficiently high reliability when being used as fuel transporting tubes for a long period in a high-temperature atmosphere.

[0007] Moreover, in the case where the low-permeation layers are used as not the respective innermost layers of tubes but the respective intermediate layers thereof, the intermediate layers may peel or separate from respective layers provided radially inwardly of the intermediate layers, in particular when being used in a high-temperature atmosphere. Thus, the tubes including, as their intermediate layers, the low-permeation layers do not exhibit a sufficiently high reliability.

[0008] By the way, Japanese Patent Document TOKU-KAI-HEI No. 7(1995)-96564 discloses a fuel transporting tube which is claimed to be able to be used as a low-permeation or anti-permeation layer against alcohol-blended gasoline, and which includes, as an anti-permeation layer, an intermediate layer formed of a polyalkylene naphthalate resin, such as polybutylene naphthalate, that exhibits a higher permeation resistance than a polyester resin, such as polybutylene terephthalate, and additionally includes an innermost layer which is formed of a fluororesin or a polyamide. Since the fuel transporting tube has a laminated structure including the above-indicated resinous innermost layer, the anti-permeation intermediate layer may separate from the innermost layer located inside the intermediate layer, because of the fuel which permeates out through the innermost layer, though an adhesive layer is provided between the intermediate layer and the innermost layer. Thus, the tube does not exhibit a sufficiently high reliability.

[0009] In particular, since the innermost layer formed of fluororesin or polyamide resin is provided inside the low-permeation or anti-permeation intermediate layer, the tube has an increased overall wall thickness, which leads to limiting the thickness of the intermediate layer, thereby limiting the anti-permeation function of the same. In addition, in the case where the innermost layer is formed of polyamide resin, the innermost layer may be less resistant to sour gasoline than the polybutylene naphthalate resin. Meanwhile, in the case where the innermost layer is formed of fluororesin, the innermost layer may exhibit a low detergent resistance, and may exhibit a low sealing characteristic because the fluororesin has a low friction coefficient and is highly slidable relative to a coupling or a metallic member being inserted into an open end of the tube.

[0010] WO 98/29245 discloses fuel containers having a multilayer laminate structure comprising one or more layers of a polyolefin or a blend of two or more polyolefines, one or more layers of a fuel barrier polymer or blend thereof and a tie layer interposed between a polyolefin layer and an adjacent fuel barrier layer.

[0011] It is therefore an object of the present invention to provide a fuel transporting tube which easily can be prepared by co-extrusion of the inner and outer layers as well as providing an inner layer for the tube with increased flexibility and softness as well as a lower melting point of the material for that inner layer. It is a further object to provide a fuel transporting tube which exhibits an excellent resistance to permeation of not only gasoline but also alcohol-blended gasoline, an excellent detergent resistance, and an excellent hydrolysis resistance, and exhibit an excellent resistance to interlayer separation when being used in a high-temperature atmosphere.

[0012] The present invention provides a fuel transporting tube as defined in claim 1 which has one or more of the technical features that are described below in respective paragraphs given parenthesized sequential numbers (1) to (16). Any feature which includes another feature shall do so by referring, at the beginning, to the parenthesized sequential number given to that feature. Thus, two or more of the following features may be combined, if appropriate. Each feature may be accompanied by a supplemental explanation, as needed.

(1) According to a first feature of the present invention, there is provided a fuel transporting tube comprising an inner layer which contacts a fuel being transported and which is formed of a polybutylene naphthalate resin as defined in claim 1; an outer layer which is provided radially outwardly of the inner layer and which is formed of a polyamide resin or a polyolefin resin; and an intermediate layer which is provided between the inner layer and the outer layer and which is formed of a resin to adhere the inner and outer layers to each other.
In the present fuel transporting tube, the inner layer that contacts the fuel being transported by the tube is formed of the polybutylene naphthalate resin. Therefore, the present tube exhibits an excellent resistance to permeation of fuels, e.g., not only common gasoline but also alcohol-blended gasoline. Even in the case where an amine detergent is added to the fuel, the present tube exhibits an excellent resistance to deterioration due to the detergent. Moreover, the present tube exhibits an excellent resistance to deterioration due to hydrolysis. Thus, the present tube exhibits a high reliability in a long-time use. Furthermore, the present tube exhibits an excellent resistance to interlayer separation when being used in a high-temperature atmosphere. The present tube does not need any additional layers inside the inner layer formed of the polybutylene naphthalate resin. Therefore, the thickness of the inner layer formed of the polybutylene naphthalate resin can be increased by the thickness of the unnecessary layer or layers, so as to improve the resistance to permeation of alcohol-blended gasoline. The polybutylene naphthalate resin exhibits a higher resistance to sour gasoline than polyamide resin, and is free of a problem with fluororesin that an innermost layer formed of the fluororesin exhibits a low sealing characteristic because a coupling or a metallic member may slide relative to the tube when being inserted in an open end of the tube.
The polybutylene naphthalate resin comprises a block-copolymer which includes, as a hard segment thereof, a polybutylene naphthalate unit, and includes, as a soft segment thereof, a polyether unit or a polyester unit. Since the inner layer of the present tube is formed of the block-copolymer as the polybutylene naphthalate resin, the softness or flexibility of the inner layer is improved. In addition, the melting point of the polybutylene naphthalate resin is lowered down to a temperature near a temperature around which the outer layer is formed of the polyamide or polyolefin resin. Thus, the inner and outer layers can be more advantageously formed by concurrent or simultaneous extrusion.

(2) According to a second feature of the present invention that includes the first feature (1), the inner layer comprises a conductive layer which is formed of a composition comprising the polybutylene naphthalate resin as defined in claim 1 and an electrically conductive material. Since the inner layer of the present tube that contacts the fuel being transported is electrically conductive, the present tube is advantageously used as a tube, e.g., a filler tube, a feed tube, or a return tube, that should be prevented from producing sparks due to discharging of electric charge.

(3) According to a third feature of the present invention that includes the first feature (1),the inner layer comprises a conductive inside layer which contacts the fuel and which is formed of a composition comprising the polybutylene naphthalate resin as defined in claim 1 and an electrically conductive material; and a non-conductive outside layer which is provided radially outwardly of the inside layer and which is formed of the polybutylene naphthalate resin and does not include any electrically conductive materials. The present tube enjoys 'the same advantage as that of the tube according to the second feature (2).

(4) According to a fourth feature of the present invention that includes any one of the first to third features (1) to (3), the intermediate layer is formed of at least one resin selected from the group consisting of a thermoplastic polyether urethane, a thermoplastic polyester urethane, a thermoplastic polyether amide elastomer, a thermoplastic polyester amide elastomer, a thermoplastic polyester elastomer, a mixture of a thermoplastic polyester elastomer and a polyamide, a mixture of a polyester and a polyamide, a maleic anhydride-modified polyolefin, an acrylic acid-modified polyolefin, an epoxy-modified polyolefin, a maleic anhydride-olefin copolymer, and an alkylacrylate-olefin copolymer. In the present tube, the intermediate layer advantageously connects the inner and outer layers to each other and thereby unifies the two layers.

(5) According to a fifth feature of the present invention that includes any one of the first to fourth features (1) to (4), at least a portion of the tube has a corrugated shape which includes at least one annular ridge and at least one annular groove which are alternate with each other and each of which extends parallel to a plane perpendicular to a lengthwise direction of the tube. The present tube as a whole can enjoy an improved flexibility, even if the inner layer formed of the polybutylene terephthalate resin may have a great thickness. Thus, the present tube enjoys not only an improved permeation resistance but also an improved ease of being handled and/or being assembled with other members.

(6) According to a sixth feature of the present invention that includes any one of the first to fifth features (1) to (5), the polybutylene naphthalate resin comprises a condensation polymerization product of a naphthalenedicarboxylic acid or its derivative capable of producing an ester, and tetramethylene glycol.

(7) According to a seventh feature of the present invention that includes the sixth feature (6), the naphthalenedicarboxylic acid is selected from the group consisting of 1,4-naphthalenedicarboxylic acid, 1,5-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, and 2,7-naphthalenedicarboxylic acid.

(8) According to an eighth feature of the present invention that includes the first or fifth feature (1) or (5), the polyether unit comprises a segment consisting of HO(CH₂CH₂O)_nH or HO(CH₂CH₂CH₂CH₂O)_nH (n is an integer).

(9) According to a ninth feature of the present invention that includes any one of the first, fifth and eight features (1), (5) and (8), the polyester unit comprises a unit selected from the group consisting of polycaprolactone, polyenantholactone, and polycaprylolactone.

(10) According to a tenth feature of the present invention that includes any one of the first, fifth, eight and ninth features (1), (5), (8) and (9), the block-copolymer includes not more than 40 parts by weight of the soft segment and not less than 60 parts by weight of the hard segment.

(11) According to an eleventh feature of the present invention that includes any one of the second to tenth features (2) to (10), the composition comprises 3 to 30 parts by weight of the electrically conductive material per 100 parts by weight of the polybutylene naphthalate resin.

(12) According to a twelfth feature of the present invention that includes any one of the first to eleventh features (1) to (11), the polyamide resin is selected from the group consisting of nylon 6, nylon 66, nylon 11, nylon 12, nylon 610, and nylon 612.

(13) According to a thirteenth feature of the present invention that includes any one of the first to twelfth features (1) to (12), the polyolefin resin is selected from the group consisting of a homopolymer and a copolymer of an olefin monomer selected from the group consisting of ethylene, propylene, butene, hexene, and octene, and a thermoplastic elastomer including, as a main component thereof, the homopolymer or the copolymer.

(14) According to a fourteenth feature of the present invention that includes any one of the first to thirteenth features (1) to (13), an outer diameter of the tube falls within a range of 8 to 50 mm, and a sum of respective thicknesses of the inner layer, the intermediate layer, and the outer layer falls within a range of 0.8 to 2.0 mm.

(15) According to a fifteenth feature of the present invention that includes any one of the first to fourteenth features (1) to (14), a thickness of the inner layer falls within a range of 0.04 to 1.0 mm, a thickness of the intermediate layer falls within a range of 0.02 to 0.5 mm, and a thickness of the outer layer falls within a range of 0.4 to 1.40 mm.

(16) According to a sixteenth feature of the present invention that includes any one of the third to fifteenth features (3) to (15), a thickness of the inside layer of the inner layer falls within a range of 5 to 50 % of a sum of respective thicknesses of the inside layer and the outside layer of the inner layer.

[0013] The above and optional objects, features and advantages of the present invention will be better understood by reading the following detailed description of the preferred embodiments of the invention when considered in conjunction with the accompanying drawings, in which:

Fig. 1 is a transverse cross section view of a fuel transporting tube as a first embodiment of the present invention;

Fig. 2 is a transverse cross section view of another fuel transporting tube as a second embodiment of the present invention; and

Fig. 3 is a plan view of a fuel transporting bellows tube as a third embodiment of the present invention.

[0014] Figs. 1 and 2 show a fuel transporting tube according to the present invention. The tube includes an inner layer 2 which contacts a fuel being transported by the tube. The inner tube 2 is formed of a polybutylene naphthalate resin. The polybutylene naphthalate resin is a condensation polymerization product of a naphthalenedicarboxylic acid or its derivative capable of producing an ester, and tetramethylene glycol. The naphthalenedicarboxylic acid is preferably selected from 1,4-naphthalenedicarboxylic acid, 1,5-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, and 2,7-naphthalenedicarboxylic acid. Out of those acids, the 2,6-naphthalenedicarboxylic acid is most preferably used.

[0015] The polybutylene naphthalate resin used to form the inner layer 2 comprises a block-copolymer which includes, as a hard segment thereof, a polybutylene naphthalate unit, and includes, as a soft segment thereof, a polyether unit or a polyester unit. The block-copolymer resin contributes to increasing the softness or flexibility of the inner layer 2, and lowering the melting point of the material used to form the inner layer 2, down to a temperature near a temperature around which an outer layer 4 is formed of a polyamide resin or a polyolefin resin as described later, so that the inner and outer layers 2, 4 can be easily co-extruded (i.e., simultaneously extruded). The polyether unit may be a segment consisting of HO(CH₂CH₂O)_nH or HO(CH₂CH₂CH₂CH₂O)_nH (n is an integer), and the polyester unit may be a unit selected from polycaprolactone, polyenantholactone, and polycaprylolactone. Generally, the block-copolymer resin includes not more than 40 parts or % by weight of the soft segment, and not less than 60 parts or % by weight of the hard segment. If the block-copolymer resin includes more than 40 parts by weight of the soft segment, the inner layer 2 formed of the block-copolymer resin cannot exhibit a sufficiently high permeation resistance.

[0016] In the case where the present fuel transporting tube is used as a specific tube, e.g., a filler tube, a feed tube, or a return tube, that should be prevented from producing sparks due to discharging of electric charge, it is preferred that the inner layer 2 is formed of a composition comprising the polybutylene naphthalate resin and an electrically conductive material. The conductive material may be selected from known materials. Preferably, conductive carbon black is used as the conductive material, and the composition includes 3 to 30 parts by weight of the carbon black per 100 parts by weight of the polybutylene naphthalate resin, so that the exposed surface of the inner layer 2 has an electric resistance of not more than 10⁸ Ω. In order that the inner layer 2 may have an effective electric conductivity due to the inclusion of the conductive carbon black, it is desirable as indicated above that the composition includes not less than 3 parts by weight of the carbon black per 100 parts by weight of the polybutylene naphthalate resin. Meanwhile, in order that the inner layer 2 may maintain an effective permeation resistance and an effective mechanical strength, it is desirable that the composition includes not more than 30 parts by weight of the carbon black per 100 parts by weight of the resin. The conductive carbon black may be Ketjenblack EC or Ketjenblack EC 600 JD available from Akzo Inc., the Netherlands.

[0017] In the case where the inner layer 2 is formed of the composition including the polybutylene naphthalate resin and the electrically conductive material, the inclusion of the conductive material leads to lowering more or less the permeation resistance of the inner layer 2. Hence, in another fuel transporting tube shown in Fig. 2, an inner layer 2 of the tube includes an inside layer 2a and an outside layer 2b, such that the inside layer 2a is formed of the composition including the polybutylene naphthalate resin and the electrically conductive material, and the outside layer 2b is formed of the polybutylene naphthalate resin and does not include any electrically conductive materials. In this case, the lowering of the permeation resistance of the inside layer 2a is compensated by the high permeation resistance of the outside layer 2b, and the inner layer 2 as a whole exhibits an effective permeation resistance.

[0018] The tube shown in Fig. 1 or the tube shown in Fig. 2 additionally includes an outer layer 4 which is provided radially outwardly of the inner layer 2. The outer layer 4 is formed of a polyamide resin or a polyolefin resin. Thus, the thickness of the inner layer 2 can be minimized, and the strength of the tube as a whole can be maintained. In addition, the outer layer 4 formed of the polyamide resin or the polyolefin resin contributes to giving flexibility or softness to the tube, thereby improving the ease of being handled or being assembled with other elements. The polyamide resin is preferably selected from nylon 6, nylon 66, nylon 11, nylon 12, nylon 610, and nylon 612. The nylon 11 or the nylon 12 is most preferably used. The polyamide resin may be mixed with one or more of a plasticizer, an elastomer, a nylon monomer, and the like, for improving the softness thereof. The polyolefin resin is preferably selected from a homopolymer and a copolymer of an olefin monomer selected from ethylene, propylene, butene, hexene, and octene, and a thermoplastic elastomer including, as a main component thereof, the homopolymer or the copolymer.

[0019] The tube shown in Fig. 1 or the tube shown in Fig. 2 further includes an intermediate layer 6 between the inner and outer layers 2, 4. The intermediate layer 6 adheres or connects the inner and outer layers 2, 4 to each other so as to provide an integral, laminated body. The intermediate layer 6 is formed of a material which is selected depending upon respective sorts of the resins used to form the inner and outer layers 2, 4. Preferably, the intermediate layer is formed of a resin selected from a thermoplastic polyether urethane, a thermoplastic polyester urethane, a thermoplastic polyether amide elastomer, a thermoplastic polyester amide elastomer, a thermoplastic polyester elastomer, a mixture of a thermoplastic polyester elastomer and a polyamide, a mixture of a polyester and a polyamide, a maleic anhydride-modified polyolefin, an acrylic acid-modified polyolefin, an epoxy-modified polyolefin, a maleic anhydride-olefin copolymer, and an alkylacrylate-olefin copolymer, or a mixture of two or more resins out of those resins.

[0020] Various dimensions of the fuel transporting tube shown in Fig. 1 or Fig. 2 are by no means limited. However, generally, the tube has an outer diameter falling within the range of 8 to 50 mm, and the sum of respective thicknesses of the inner layer 2, the intermediate layer 6, and the outer layer 4 falls within the range of 0.8 to 2.0 mm. The respective thicknesses of the inner layer 2, the intermediate layer 6, and the outer layer 4 are so determined that the three layers 2, 4, 6 can function as required. Generally, the thickness of the inner layer falls within the range of 0.04 to 1.0 mm, the thickness of the intermediate layer falls within the range of 0.02 to 0.5 mm, and the thickness of the outer layer falls within the range of 0.4 to 1.40 mm. In the tube shown in Fig. 2, the thickness of the inside layer 2a of the inner layer 2 falls within the range of 5 to 50 % of the sum of respective thicknesses of the inside layer 2a and the outside layer 2b.

[0021] The fuel transporting tube shown in Fig. 1 or Fig. 2 may be provided, as needed, with a protector tube, such as a solid tube or a sponge tube, outside the outer layer 4, so that the tube is protected by the protector tube against flame or splashed pebbles. The solid tube or the sponge tube may be formed of EPDM, EPM, or the like. The protector tube may be formed on the outer surface of the outer layer 4, such that the protector tube is integrally connected to the outer layer 4. Alternatively, the protector tube may be formed as a separate member, and is externally fitted on the outer surface of the outer layer 4.

[0022] The fuel transporting tube shown in Fig. 1 or Fig. 2 may be manufactured in a conventional method in which the inner layer 2, the intermediate layer 6, and the outer layer 4 are sequentially formed in the order of description to provide a tube having a laminated structure. Alternatively, the three layers 2, 6, 4 may be simultaneously extruded (i.e., co-extruded) to provide a tube having an integral, laminated structure. Preferably, in order to improve the degree of adhesiveness among the three layers 2, 4, 6, the three layers 2, 4, 6 are simultaneously extruded to provide a target tube having an integral, laminated structure.

[0023] While the fuel transporting tube shown in Fig. 1 or Fig. 2 is a smooth tube whose outer circumferential surface is smooth, a fuel transporting tube according to the present invention may be a bellows tube at least a portion of which has a corrugated shape including one or more annular ridges and one or more annular grooves which are alternate with each other and each of which extends parallel to a plane perpendicular to a lengthwise or axial direction of the tube. Fig. 3 shows a fuel transporting bellows tube including an axially intermediate bellows portion 8 and two axially end smooth portions 10 located on both sides of the bellows portion 8. Since the bellows portion 8 has an improved flexibility, the bellows tube enjoys not only an improved permeation resistance but also an improved ease of being handled or being assembled with other elements.

[0024] In the case where the inner layer 2, the intermediate layer 6, and the outer layer 4 are simultaneously extruded, first, respective resin materials used to form the three layers 2, 4, 6 are put in respective hoppers of three extruders (or four extruders in the case where the inner layer 2 consists of the inside layer 2a and the outside layer 2b). Subsequently, the three layers 2, 4, 6 (or the four layers 2a, 2b, 4, 6) are simultaneously extruded from a common die at a temperature of 160 to 280 °C, so as to provide a tube having an integral, laminated structure. In the case where a smooth tube is produced, the extruded tube is passed through a cooling device via a sizing die and then is taken up by a take-up machine. Thus, a target tube is obtained. Meanwhile, in the case where a bellows tube as shown in Fig. 3 is produced, the extruded tube is passed through a corrugater machine in which a forming die having a corrugated shape and a forming die having a smooth shape are arranged, and thus a target tube is obtained. In the latter case, if only the forming die having the smooth shape is provided in the corrugater machine, a smooth tube can be obtained.

[0025] Hereinafter, some examples of a fuel transporting tube according to the present invention will be described in more detail to elucidate the nature of the present invention.

[0026] Various sorts of invention tubes are obtained as follows: Each invention tube is a bellows tube, as shown in Fig. 3, which includes an intermediate bellows portion 8 having an outer diameter of 36 mm and an axial length of 300 mm, and two axially end smooth portions 10 each having an outer diameter of 32 mm and an axial length of 100 mm. Each invention tube has a laminated structure as shown in Fig. 1 or Fig. 2, and has an overall wall thickness of 1 mm and an overall axial length of 500 mm. Each invention tube is formed of resin materials indicated in TABLE 1 to TABLE 7, and respective layers 2 (2a, 2b), 4, 6 of each invention tube are formed to have respective thicknesses indicated in the tables. The invention tubes are produced in the conventional simultaneous-extrusion method.

[0027] The polybutylene naphthalate resin (hereinafter referred to as "PBN") used to produce the invention tubes is obtained by using, as the naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid. A first conductive composition ("1st CC") including PBN and an electrically conductive material is obtained by mixing 100 parts by weight of PBN and 10 parts by weight of Ketjenblack EC 600 JD and uniformly kneading, using a two-axis kneading machine, the thus obtained mixture. The PBN-polyether block-copolymer used is a first block-copolymer including, as its hard segments, 80 % by weight of PBN units, and including, as its soft segments, 20 % by weight of polytetramethylene glycol units. A second conductive composition ("2nd CC") including a PBN-polyether block-copolymer and an electrically conductive material is obtained by mixing 100 parts by weight of the above-indicated first block-copolymer and 10 parts by weight of Ketjenblack EC 600 JD and uniformly kneading, using the two-axis kneading machine, the thus obtained mixture.

[0028] The PBN-polyester block-copolymer used is a second block-copolymer including, as its hard segments, 80 % by weight of PBN units, and including, as its soft segments, 20 % by weight of polycaprolactone units. A third conductive composition ("3rd CC") including a PBN-polyester block-copolymer and an electrically conductive material is obtained by mixing 100 parts by weight of the above-indicated second block-copolymer and 10 parts by weight of Ketjenblack EC 600 JD and uniformly kneading, using the two-axis kneading machine, the thus obtained mixture.

[0029] In the tables, "PE" is an abbreviation of polyethylene and "PP" is an abbreviation of polypropylene.

[0030] Each of the thus obtained invention tubes is tested and evaluated regarding its fuel-permeation resistance, detergent resistance, hydrolysis resistance, and interlayer-separation resistance, according to the below-explained methods, and the obtained results are shown in the same tables.

FUEL-PERMEATION RESISTANCE

[0031] A standard gasoline or fuel, Fuel C ("FC"), or an alcohol-blended gasoline or fuel ("M15") including 85 % by volume of FC and 15 % by volume of methanol, is put in each test tube and is kept in a thermostat held at 40 °C. Each time 24 hours elapse, each tube is taken out of the thermostat, and a decreased weight of each tube is measured. This procedure is repeated twenty times, and the largest one of the measured decreased weights is chosen to calculate a fuel permeation amount per meter (of tube) per day (mg/m/day).

DETERGENT RESISTANCE

[0032] Dodecamethylenediamine as a sort of amine is used as an amine detergent. A standard fuel, Fuel C, including dodecamethylenediamine in an amount of 0.05 mol/L is put in each test tube and is kept in a thermostat held at 80 °C. 200 and 400 hours after, each tube is taken out of the thermostat, and the fuel is removed from the tube. Then, each tube is folded by 180 degrees, and whether any cracks are present in the inner surface of the tube is checked. A tube free of cracks 400 hours after is evaluated "A"; a tube with cracks 400 hours after is evaluated "B"; and a tube with cracks 200 hours after is evaluated "C".

HYDROLYSIS RESISTANCE

[0033] A solution including 15 % by volume of methanol and 85 % by volume of water is put in each test tube and is kept in a thermostat held at 80 °C. 1500 and 3000 hours after, each tube is taken out of the thermostat, and the solution is removed from the tube. Then, each tube is folded by 180 degrees, the folded portion of the tube is cut, and whether any cracks are present in the cut surface of the tube is checked. A tube free of cracks 3000 hours after is evaluated "A"; a tube with cracks 3000 hours after is evaluated "B"; and a tube with cracks 1500 hours after is evaluated "C".

INTERLAYER-SEPARATION RESISTANCE

[0034] The alcohol-blended fuel, i.e., M15 is put in each test tube and is kept in a thermostat held at 60 °C, for 168 hours. Then, the fuel is removed from each tube and is kept in the thermostat held at 80 °C for 72 hours. This procedure is repeated three times, and a peeling test is carried out according to JIS-K-6256 ("JIS" is Japanese Industrial Standard). More specifically described, a 25 mm long ring-like axial portion of each tube is cut off, and the thus obtained axial portion is cut and opened along a longitudinal axis line thereof. Thus, a test specimen is obtained. Then, in the case of a test tube including, as its inner layer, an anti-permeation layer, the inner layer and an intermediate layer of the tube, appearing in the cut surface of the same, are fixed to two grippers of a tensile testing machine, respectively. Meanwhile, in the case of a test tube including, as its intermediate layer, an anti-permeation layer, the layers inside the anti-permeation intermediate layer, and the outside layers including the anti-permeation intermediate layer, all appearing in the cut surface of the tube, are fixed to the two grippers of the tensile testing machine, respectively. Then, the two grippers are drawn in opposite directions at a speed of 25 mm/min. Thus, a separation-resistant strength (or adhesive strength) is measured. A tube having a separation-resistant ("SR") strength of not less than 2 N/mm is evaluated "A"; a tube which has an SR strength of not less than 1 N/mm and not more than 2 N/mm is evaluated "B"; and a tube which has an SR strength of not more than 1 N/mm is evaluated "C".

[0035] As is apparent from the results shown in TABLE 1 to TABLE 7, all the invention tubes each including the inner layer (2) formed of the PBN as defined in claim 1 exhibit excellent fuel-permeation resistance, detergent resistance, hydrolysis resistance, and interlayer-separation resistance. On the other hand, comparative tubes 1, 2 whose inner layer is formed of polybutylene terephthalate ("PBT") or polyethylene naphthalate ("PEN") each as a polyester resin, exhibit insufficiently low fuel-permeation resistance, detergent resistance, and hydrolysis resistance. Likewise, comparative multi-layer tubes 3, 4 whose intermediate layer is formed of PBT and which have two adhesive layers, one between the intermediate layer and the inner layer and the other between the intermediate layer and the outer layer, exhibit insufficiently low fuel-permeation resistance, detergent resistance, and hydrolysis resistance.

[0036] As is apparent from the foregoing description, the fuel transporting tubes according to the present invention enjoy an excellent resistance to permeation of fuels, e.g., not only gasoline but also alcohol-blended gasoline, an excellent detergent resistance, and an excellent hydrolysis-deterioration resistance, and exhibits an excellent resistance to interlayer separation when being used in a high-temperature atmosphere, and which is particularly suitable for use in a fuel-transporting piping system of an automotive vehicle. Thus, the invention tubes are sufficiently promising for future practical use.
A fuel transporting tube including an inner layer (2) which contacts a fuel being transported and which is formed of a polybutylene naphthalate resin as defined in claim 1, an outer layer (4) which is provided radially outwardly of the inner layer and which is formed of a polyamide resin or a polyolefin resin, and an intermediate layer (6) which is provided between the inner layer and the outer layer and which is formed of a resin to adhere the inner and outer layers to each other.

Claims

1. A fuel transporting tube comprising:

an inner layer (2) which contacts a fuel being transported and which is formed of a polybutylene naphthalate resin;

an outer layer (4) which is provided radially outwardly of the inner layer and which is formed of a polyamide resin or a polyolefin resin; and

an intermediate layer (6) which is provided between the inner layer and the outer layer and which is formed of a resin to adhere the inner and outer layers to each other;

   characterized in that the polybutylene naphthalate resin comprises a block-copolymer which includes, as a hard segment thereof, a polybutylene naphthalate unit, and includes, as a soft segment thereof, a polyether unit or a polyester unit.

2. The tube according to claim 1, wherein the inner layer (2) comprises a conductive layer (2a) which is formed of a composition comprising the polybutylene naphthalate resin and an electrically conductive material.

3. The tube according to claim 1, wherein the inner layer (2) comprises:

a conductive inside layer (2a) which contacts the fuel and which is formed of a composition comprising the polybutylene naphthalate resin and an electrically conductive material; and

a non-conductive outside layer (2b) which is provided radially outwardly of the inside layer and which is formed of the polybutylene naphthalate resin and does not include any electrically conductive materials.

4. The tube according to any one of claims 1 to 3, wherein the intermediate layer (6) is formed of at least one resin selected from the group consisting of a thermoplastic polyether urethane, a thermoplastic polyester urethane, a thermoplastic polyether amide elastomer, a thermoplastic polyester amide elastomer, a thermoplastic polyester elastomer, a mixture of a thermoplastic polyester elastomer and a polyamide, a mixture of a polyester and a polyamide, a maleic anhydride-modified polyolefin, an acrylic acid-modified polyolefin, an epoxy-modified polyolefin, a maleic anhydride-olefin copolymer, and an alkylacrylate-olefin copolymer.

5. The tube according to any one of claims 1 to 4, wherein at least a portion of the tube has a corrugated shape (8) which includes at least one annular ridge and at least one annular groove which are alternate with each other and each of which extends parallel to a plane perpendicular to a lengthwise direction of the tube.

6. The tube according to any one of claims 1 to 5, wherein the polybutylene naphthalate resin comprises a condensation polymerization product of a naphthalenedicarboxylic acid or its derivative capable of producing an ester, and tetramethylene glycol.

7. The tube according to claim 6, wherein the naphthalenedicarboxylic acid is selected from the group consisting of 1,4-naphthalenedicarboxylic acid, 1,5-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, and 2,7-naphthalenedicarboxylic acid.

8. The tube according to any one of claims 1 to 7, wherein the polyether unit comprises a segment consisting of HO(CH₂CH₂O)_nH or HO(CH₂CH₂CH₂CH₂O)_nH (n is an integer).

9. The tube according to any one of claims 1 to 8, wherein the polyester unit comprises a unit selected from the group consisting of polycaprolactone, polyenantholactone, and polycaprylolactone.

10. The tube according to any one of claims 1 to 9, wherein the block-copolymer includes not more than 40 parts by weight of the soft segment and not less than 60 parts by weight of the hard.segment.

11. The tube according to any of claims 2 to 10, wherein the composition comprises 3 to 30 parts by weight of the electrically conductive material per 100 parts by weight of the polybutylene naphthalate resin.

12. The tube according to any one of claims 1 to 11, wherein the polyamide resin is selected from the group consisting of nylon 6, nylon 66, nylon 11, nylon 12, nylon 610, and nylon 612.

13. The tube according to any one of claims 1 to 12, wherein the polyolefin resin selected from the group consisting of a homopolymer and a copolymer of an olefin monomer selected from the group consisting of ethylene, propylene, butene, hexene, and octene, and a thermoplastic elastomer including, as a main element thereof, the homopolymer or the copolymer.

14. The tube according to any one of claims 1 to 13, wherein an outer diameter of the tube falls within a range of 8 to 50 mm, and a sum of respective thicknesses of the inner layer, the intermediate layer, and the outer layer falls within a range of 0.8 to 2.0 mm.

15. The tube according to any one of claims 1 to 14, wherein a thickness of the inner layer falls within a range of 0.04 to 1.0 mm, a thickness of the intermediate layer falls within a range of 0.02 to 0.5 mm, and a thickness of the outer layer falls within a range of 0.4 to 1.40 mm.

16. The tube according to any one of claims 3 to 15, wherein a thickness of the inside layer of the inner layer falls within a range of 5 to 50 % of a sum of respective thicknesses of the inside layer and the outside layer of the inner layer.

Ansprüche

1. Eine Kraftstofftransportröhre, umfassend:

eine innere Schicht (2), welche mit einem zu transportierenden Kraftstoff in Kontakt steht und welche aus einem Polybutylennaphthalatharz ausgebildet ist;

eine äußere Schicht (4), welche radial um die innere Schicht vorgesehen ist und welche aus einem Polyamidharz oder einem Polyolefinharz ausgebildet ist; und

eine Zwischenschicht (6), welche zwischen der inneren Schicht und der äußeren Schicht vorgesehen ist und welche aus einem Harz ausgebildet ist, um die innere und die äußere Schicht miteinander zu verkleben;

dadurch gekennzeichnet, dass
das Polybutylennaphthalatharz ein Blockcopolymer umfasst, welches als dessen hartes Segment eine Polybutylennaphthalateinheit mit einschließt und welches als dessen weiches Segment eine Polyethereinheit oder eine Polyestereinheit mit einschließt.

2. Röhre gemäß Anspruch 1, wobei die innere Schicht (2) eine leitfähige Schicht (2a) umfasst, welche aus einer Zusammensetzung ausgebildet ist, die ein Polybutylennaphthalatharz und ein elektrisch leitfähiges Material umfasst.

3. Röhre gemäß Anspruch 1, wobei die innere Schicht (2) folgendes umfasst:

eine leitfähige Innenschicht (2a), welche mit dem Kraftstoff in Kontakt steht und welche aus einer Zusammensetzung ausgebildet ist, die ein Polybutylennaphthalatharz und ein elektrisch leitfähiges Material umfasst; und

eine nicht leitfähige Außenschicht (2b), welche radial um die Innenschicht vorgesehen ist und welche aus dem Polybutylennaphthalatharz ausgebildet ist und keine elektrisch leitfähigen Materialien mit einschließt.

4. Röhre gemäß einem der Ansprüche 1 bis 3, wobei die Zwischenschicht (6) aus wenigstens einem Harz ausgebildet ist, das aus der Gruppe ausgewählt ist, die aus einem thermoplastischen Polyetherurethan, einem thermoplastischen Polyesterurethan, einem thermoplastischen Polyetheramidelastomer, einem thermoplastischen Polyesteramidelastomer, einem thermoplastischen Polyesterelastomer, einer Mischung aus einem thermoplastischen Polyesterelastomer und einem Polyamid, einer Mischung aus einem Polyester und einem Polyamid, einem mit Maleinsäureanhydrid-modifizierten Polyolefin, einem mit Acrylsäure-modifizierten Polyolefin, einem mit Epoxid-modifizierten Polyolefin, einem Maliensäureanhydrid/Olefin-Copolymer und einem Alkylacrylat/Olefin-Copolymer besteht.

5. Röhre gemäß einem der Ansprüche 1 bis 4, wobei wenigstens ein Teil der Röhre eine gerippte Gestalt (8) hat, die wenigstens eine kreisförmige Rippe und wenigstens eine kreisförmige Rille mit einschließt, welche sich miteinander abwechseln, und wobei sie sich jeweils parallel zu einer senkrecht auf einer Längsrichtung der Röhre stehenden Ebene erstrecken.

6. Röhre gemäß einem der Ansprüche 1 bis 5, wobei das Polybutylennaphthalatharz ein Kondensationspolymerisationsprodukt einer Naphthalindicarbonsäure oder eines Derivats davon, das einen Ester erzeugen kann, mit Tetramethylenglykol umfasst.

7. Röhre gemäß Anspruch 6, wobei die Naphthalindicarbonsäure aus der Gruppe ausgewählt ist, die aus 1,4-Naphthalindicarbonsäure, 1,5-Naphthalindicarbonsäure, 2,6- Naphthalindicarbonsäure und 2,7- Naphthalindicarbonsäure besteht.

8. Röhre gemäß einem der Ansprüche 1 bis 7, wobei die Polyethereinheit ein Segment umfasst, das aus HO(CH₂CH₂O)_nH oder HO(CH₂CH₂CH₂CH₂O)_nH (n ist eine ganze Zahl) besteht.

9. Röhre gemäß einem der Ansprüche 1 bis 8, wobei die Polyestereinheit eine Einheit umfasst, die aus der Gruppe ausgewählt ist, die aus Polycaprolacton, Polyenantholacton und Polycaprylolacton besteht.

10. Röhre gemäß einem der Ansprüche 1 bis 9, wobei das Blockcopolymer nicht mehr als 40 Gew.-Teile des weichen Segments und nicht weniger als 60 Gew.-Teile des harten Segments mit einschließt.

11. Röhre gemäß einem der Ansprüche 2 bis 10, wobei die Zusammensetzung 3 bis 30 Gew.-Teile des elektrisch leitfähigen Materials pro 100 Gew.-Teilen des Polybutylennaphthalatharzes umfasst.

12. Röhre gemäß einem der Ansprüche 1 bis 11, wobei das Polyamidharz aus der Gruppe ausgewählt ist, die aus Nylon 6, Nylon 66, Nylon 11, Nylon 12, Nylon 610 und Nylon 612 besteht.

13. Röhre gemäß einem der Ansprüche 1 bis 12, wobei das Polyolefinharz aus der Gruppe ausgewählt ist, die aus einem Homopolymer und einem Copolymer eines Olefinmonomers, ausgewählt aus der aus Ethylen, Propylen, Buten, Hexen und Octen bestehenden Gruppe, mit einem thermoplastischen Elastomer, das als eine Hauptkomponente das Homopolymer oder das Copolymer mit einschließt, besteht.

14. Röhre gemäß einem der Ansprüche 1 bis 13, wobei ein äußerer Durchmesser der Röhre innerhalb eines Bereichs von 8 bis 50 mm fällt, und eine Summe der entsprechenden Dicken der inneren Schicht, der Zwischenschicht und der äußeren Schicht innerhalb eines Bereichs von 0,8 bis 2,0 mm fällt.

15. Röhre gemäß einem der Ansprüche 1 bis 14, wobei eine Dicke der inneren Schicht innerhalb eines Bereichs von 0,04 bis 1,0 mm fällt, eine Dicke der Zwischenschicht innerhalb eines Bereichs von 0,02 bis 0,5 mm fällt und eine Dicke der äußeren Schicht innerhalb eines Bereichs von 0,4 bis 1,40 mm fällt.

16. Röhre gemäß einem der Ansprüche 3 bis 15, wobei eine Dicke der Innenschicht der inneren Schicht innerhalb eines Bereichs von 5 bis 50 % einer Summe der entsprechenden Dicke der Innenschicht und der Außenschicht der inneren Schicht fällt.

Revendications

1. Tube pour transport de carburant comprenant :

une couche intérieure (2) qui est en contact avec un carburant transporté et qui est constituée d'une résine naphtalate de polybutylène ;

une couche extérieure (4) qui est disposée radialement à l'extérieur de la couche intérieure et qui est formée d'une résine polyamide ou d'une résine polyoléfine ; et

une couche intermédiaire (6) qui est disposée entre la couche intérieure et la couche extérieure et qui est formée d'une résine pour faire adhérer l'une à l'autre les couches intérieure et extérieure ;

   caractérisé en ce que la résine naphtalate de polybutylène comprend un copolymère à blocs qui inclut une unité naphtalate de polybutylène qui en constitue un segment dur et une unité de polyéther ou de polyester qui en constitue un segment souple.

2. Tube selon la revendication 1, dans lequel la couche intérieure (2) comprend une couche conductrice (2a) qui est formée d'une composition comprenant la résine naphtalate de polybutylène et un matériau électriquement conducteur.

3. Tube selon la revendication 1, dans lequel la couche intérieure (2) comprend :

une couche interne conductrice (2a), qui est en contact avec l'essence et qui est formée d'une composition comprenant la résine naphtalate de polybutylène et un matériau électriquement conducteur ; et

une couche externe non conductrice (2b) qui est disposée radialement à l'extérieur de la couche interne et qui est formée de la résine naphtalate de polybutylène et n'inclut pas de matériaux électriquement conducteurs.

4. Tube selon l'une des revendications 1 à 3, dans lequel la couche intermédiaire (6) est constituée d'au moins une résine choisie dans le groupe constitué par un polyéther-uréthanne thermoplastique, un polyester-uréthanne thermoplastique, un élastomère thermoplastique de polyéther-amide, un élastomère thermoplastique de polyester-amide, un élastomère thermoplastique de polyester, un mélange d'un élastomère thermoplastique de polyester et d'un polyamide, un mélange d'un polyester et d'un polyamide, une polyoléfine modifiée anhydride maléique, une polyoléfine modifiée acide acrylique, une polyoléfine modifiée époxy, un copolymère d'oléfine et d'anhydride maléique, et un copolymère oléfine-alkylacrylate.

5. Tube selon l'une des revendications 1 à 4, dans lequel au moins une portion du tube a une forme ondulée (8) qui inclut au moins une nervure annulaire et au moins une rainure annulaire qui alternent l'une avec l'autre et dont chacune s'étend parallèlement à un plan perpendiculaire à la direction longitudinale du tube.

6. Tube selon l'une des revendications 1 à 5, dans lequel la résine de naphtalate de polybutylène comprend un produit de polymérisation par condensation d'un acide naphtalènedicarboxylique ou de son dérivé capable de produire un ester, et de tétraméthylène glycol.

7. Tube selon la revendication 6, dans lequel l'acide naphtalènedicarboxylique est choisi dans le groupe constitué par l'acide 1,4-naphtalènedicarboxylique, l'acide 1,5-naphtalènedicarboxylique, l'acide 2,6-naphtalènedicarboxylique et l'acide 2, 7-naphtalènedicarboxylique.

8. Tube selon l'une des revendications 1 à 7, dans lequel l'unité polyéther comprend un segment constitué par HO(CH₂CH₂O)_nH ou HO(CH₂CH₂CH₂CH₂O)_nH (n étant un entier).

9. Tube selon l'une des revendications 1 à 8, dans lequel l'unité polyester comprend une unité choisie dans le groupe constitué par le polycaprolactone, le polyénantholactone, et le polycaprylolactone.

10. Tube selon l'une des revendications 1 à 9, dans lequel le copolymère à blocs n'inclut pas plus de 40 parties en poids de segment souple et pas moins de 60 parties en poids de segment dur.

11. Tube selon l'une des revendications 2 à 10, dans lequel la composition comprend de 3 à 30 parties en poids de matériau électriquement conducteur pour 100 parties en poids de résine naphtalate de polybutylène.

12. Tube selon l'une des revendications 1 à 11, dans lequel la résine polyamide est choisie dans le groupe constitué par le Nylon 6, le Nylon -6,6, le Nylon 11, le Nylon 12, le Nylon 610, et le Nylon 612.

13. Tube selon l'une des revendications 1 à 12, dans lequel la résine polyoléfine est choisie dans le groupe constitué par un homopolymère et un copolymère d'un monomère oléfinique choisi dans le groupe constitué par l'éthylène, le propylène, le butène, l'hexène et l'octène, et un élastomère thermoplastique incluant, comme unité principale, l'homopolymère ou le copolymère.

14. Tube selon l'une des revendications 1 à 13, dans lequel le diamètre extérieur du tube se situe dans une plage allant de 8 à 50 mm, et la somme des épaisseurs respectives de la couche intérieure, de la couche intermédiaire, et de la couche extérieure se situe dans une plage allant de 0,8 à 2,0 mm.

15. Tube selon l'une des revendications 1 à 14, dans laquelle l'épaisseur de la couche intérieure se situe dans une plage allant de 0,04 à 1,0 mm, l'épaisseur de la couche intermédiaire se situe dans une plage allant de 0,02 à 0,5 mm, et l'épaisseur de la couche extérieure se situe dans une plage allant de 0,4 à 1,40 mm.

16. Tube selon l'une des revendications 3 à 15, dans lequel l'épaisseur de la couche interne de la couche intérieure se situe dans une plage allant de 5 à 50% de la somme des épaisseurs respectives de la couche interne et de la couche externe de la couche intérieure.

Drawing